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Retrofit machine monitoring and data collection system

Operating conditions in today’s manufacturing industry are constantly changing. Increasing complexity reduces transparency of the operation which itself can lead to reduced productivity. This is a simple reality for many companies today. In order to release trapped potential in the machine shop and on manual workstations a simple universal system for identifying and measuring non-productive time is essential – irrespective of machine type or age.

Werma has the solution – SmartMONITOR

Werma’s SmartMONITOR helps to make processers lean, faster and more efficient. The wireless based data collection and transmission system is easy to retrofit and enables analysis of the operation which in turn will lead to untapping growth potential and keeping you one step ahead of the competition.

“SmartMONITOR is the intelligent machine monitoring system alternative for companies who are looking for a quick and uncomplicated way of optimising their processes” comments Christian Höhler, Technical Director at Werma who continues; “the system will provide you with all relevant data on the performance of machines, equipment and manual workstations, simply with a couple of mouse clicks.”

SmartMONITOR keeps you in control

In stark contrast to other more complex machine data collection systems, SmartMONITOR provides a comprehensive overview and analysis of machine and workstation performance. Easy to retrofit, the system transmits the data wirelessly and therefore considerably reduces and simplifies installation.

Control station displays on the PC or automatic notification to your smartphone will help to reduce reaction to downtime considerably and help identify ways of optimising manufacturing processes. Detailed reports and analyses of the data can be produced automatically which will then show the possibilities to improve processes and increase productivity.

Many applications

SmartMONITOR can be used in machine shops, automation processes and logistics applications, to name but a few. For example, when deployed as a machine monitoring system, downtime and waiting times can be identified and reduced and productivity increased. The operation will benefit from improved transparency and the system can be installed on virtually any machine and equipment, irrespective of type or age,The wireless based system will provide transparency of operations dispersed over large areas or in multiple locations and help identify untapped capacity reserves.Manual workstations can also be integrated into the system and a “head of line” function allows machinery and equipment to be networked together enabling simple stop/start control.

The system – simple yet clever

Werma’s SmartMONITOR consists of a receiver, wireless transmitters and a software package. The tried and tested robust system generates its own network for monitoring of machines and equipment and sits alongside its own manufacturing process tools. The integrated software package comes with integrated analytical and report tools.

The software is very easy to install and intuitive to use. The status condition of signal towers used in the monitoring process are displayed on a control station view and in other displays the user can analyse productivity, review fault conditions and thereby start to improve the efficiency of the equipment.

The wireless transmitter unit is simply added to an existing Werma signal tower stack and is used to monitor the status of or output of machines and equipment. Status changes and output generated are transmitted wirelessly to the receiver unit and from there on it is logged securely in an SQL databased on the software.

System recognised with an award

The innovative machine and workstation monitoring system has been recognised with an award in the German “100 locations for Industry 4.0 in the State of Baden-Württemberg” competition. This competition, organised by the Baden-Württemberg Alliance for Industry 4.0, searched for innovative concepts from industry which linked successfully value adding processes within a network. The jury evaluated not only the theoretical aspect of the concept, but also its practical application.

“We are thrilled to have received this award for our Industry 4.0 solution which is particularly gratifying to have received it from within our home state in Germany” says Werma UK MD Simon Adams, “it shows that we are on the right path with our monitoring system.”